System and method for controlling engine revolutions for hybrid construction machine

ABSTRACT

A system and method for controlling engine revolutions for a hybrid construction machine, including an engine, a hydraulic pump which is driven by the engine to drive a hydraulic actuator with discharged hydraulic fluid, a motor-generator which is driven by the engine to generate electricity and to drive the hydraulic pump as a motor supplementing the engine, an energy storage device which is charged with electric energy generated by the motor-generator and which supplies the electric energy for motor operation of the motor-generator, a torque detection unit for detecting an output torque of the hydraulic pump that is required to drive the hydraulic actuator, and a hybrid control unit for controlling the motor operation of the motor-generator to supplement the engine output if the change of the output torque of the hydraulic pump exceeds a predetermined level and it is determined that an engine revolution drop will occur.

CROSS-REFERENCE TO RELATED APPLICATION Related Application

This application is a divisional of application Ser. No. 12/819,495filed on Jun. 21, 2010, the entire contents of which are incorporatedherein by reference.

This application is based on and claims priority from Korean PatentApplication No. 10-2009-69576, filed on Jul. 29, 2009 in the KoreanIntellectual Property Office, the disclosure of which is incorporatedherein in its entirety by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a system and method for controllingengine revolutions for a hybrid construction machine. More particularly,the present invention relates to a system and method for controllingengine revolutions for a hybrid construction machine, which can preventthe occurrence of engine revolution drop in a hybrid constructionmachine.

2. Description of the Prior Art

In general, a construction machine such as an excavator in the relatedart has a hydraulic driving system which drives a hydraulic pump by afuel engine and drives an actuator by hydraulic pressure.

FIG. 1 is a necessary torque output relationship diagram of an excavatorsystem in the related art. As illustrated in FIG. 1, in a hydraulicexcavator in the related art, an opening area of a main control valve(MCV) 7 is adjusted in accordance with an output of a pilot valve 6through a user's manipulation of a lever 5. Hydraulic fluid dischargedfrom a hydraulic pump 13 is transferred to respective hydraulic systemswith its flow rate adjusted in accordance with the opening area of theMCV 7. Since the driving of the hydraulic pump 13 is performed by a fuelengine 10, the efficiency thereof is relatively low.

In the construction machine such as the hydraulic excavator in therelated art, it is sometimes required to perform working as greatlychanging an engine output so as to cope with great load change, and itis required to seek improvement of mileage by effectively utilizing theengine output. Accordingly, a hybrid technology using an electricmotor-generator that is adopted in a hybrid vehicle has been planned tobe applied to an excavator. That is, a hybrid construction machine, suchas a hybrid excavator, in which an engine is connected to an electricmotor-generator, has been proposed. According to the hybrid constructionmachine, in the case of performing a light-load operation, themotor-generator is operated to generate power to charge a battery usinga portion of the engine output, while in the case of performing aheavy-load operation, electric energy is provided from the battery tosupplement the engine.

An electric motor-generator is attached to the engine of the hybridexcavator. If this electric motor-generator is abruptly operated, enginerevolutions (i.e. revolutions per minute (RPM)) may be lowered to causethe occurrence of an engine revolution (RPM) drop. Although the enginereturns to its original revolutions by a self-control system, theworking performance is lowered in this process.

Also, the lowering of the engine revolution occurs when the load isgreatly changed, for example, the load is abruptly increased, duringoperation of the construction machine.

SUMMARY OF THE INVENTION

Accordingly, the present invention has been made to solve theabove-mentioned problems occurring in the prior art while advantagesachieved by the prior art are maintained intact.

The present invention proposes to improve an engine revolution (RPM)drop which occurs during the operation of a hybrid excavator or due toan abrupt operation change of a motor-generator attached to an engine.

The present invention also proposes to provide a system and method forcontrolling engine revolutions for a hybrid construction machine, whichcan improve an engine revolution (RPM) drop by supplementing an engineoutput through operation of a motor-generator as a motor when the RPMdrop occurs.

The present invention also proposes to provide a system and method forcontrolling engine revolutions for a hybrid construction machine, whichcan smoothly change and process a driving signal of a motor-generator soas to prevent the occurrence of an abrupt change of engine revolutions(RPM) due to an abrupt operation of the motor-generator attached to anengine of the hybrid construction machine.

In one aspect of the present invention, there is provided a system forcontrolling engine revolutions for a hybrid construction machine,including an engine, a hydraulic pump which is driven by the engine todrive a hydraulic actuator with discharged hydraulic fluid, amotor-generator which is driven by the engine to generate electricityand to drive the hydraulic pump as a motor supplementing the engine, andan energy storage device which is charged with electric energy generatedby the motor-generator and which supplies the electric energy for motoroperation of the motor-generator, which further includes a torquedetection means for detecting an output torque of the hydraulic pumpthat is required to drive the hydraulic actuator; and a hybrid controlmeans for controlling the motor operation of the motor-generator so asto supplement the engine output if the change of the output torque ofthe hydraulic pump detected by the torque detection means exceeds apredetermined level and it is determined that an engine revolution dropwill occur.

In the system for controlling engine revolutions according to apreferred embodiment of the present invention, the hybrid control meanscontrols the motor operation of the motor-generator so as to supplementthe engine output if the change of the output torque of the hydraulicpump exceeds the predetermined level due to an abrupt increase of loadand it is determined that the engine revolution drop will occur.

The system for controlling engine revolutions according to a preferredembodiment of the present invention further includes a driving controlmeans for controlling power generation or the motor operation of themotor-generator; and an abrupt operation detection means for detectingwhether the motor-generator is abruptly operated; wherein the hybridcontrol means smoothly processes an abrupt operation signal of themotor-generator and supplies the processed signal to the driving controlmeans if the change of the output torque of the hydraulic pump that isrequired according to the abrupt operation of the motor-generatordetected by the abrupt operation detection means exceeds thepredetermined level and it is determined that the engine revolution dropwill occur.

In another aspect of the present invention, there is provided a methodfor controlling engine revolutions in a control system for a hybridconstruction machine, including an engine, a hydraulic pump which isdriven by the engine to drive a hydraulic actuator with dischargedhydraulic fluid, a motor-generator which is driven by the engine togenerate electricity and to drive the hydraulic pump as a motorsupplementing the engine, and an energy storage device which is chargedwith electric energy generated by the motor-generator and which suppliesthe electric energy for motor operation of the motor-generator, themethod for controlling engine revolutions includes a torque detectionstep of detecting an output torque of the hydraulic pump that isrequired to drive the hydraulic actuator; a drop determination step ofdetermining the possibility of generating an engine revolution drop ifthe change of the output torque of the hydraulic pump detected in thetorque detection step exceeds a predetermined level; and a hybridcontrol step of controlling the motor operation of the motor-generatorso as to supplement the engine output if it is determined that theengine revolution drop will occur in the drop determination step.

In the method for controlling engine revolutions according to apreferred embodiment of the present invention, the drop determinationstep determines the possibility of generating the engine revolution dropif the change of the output torque of the hydraulic pump exceeds thepredetermined level due to an abrupt increase of load during operation.

In still another aspect of the present invention, there is provided amethod for controlling engine revolutions in a control system for ahybrid construction machine, including an engine, a hydraulic pump whichis driven by the engine to drive a hydraulic actuator with dischargedhydraulic fluid, a motor-generator which is driven by the engine togenerate electricity and to drive the hydraulic pump as a motorsupplementing the engine, and an energy storage device which is chargedwith electric energy generated by the motor-generator and which suppliesthe electric energy for motor operation of the motor-generator, themethod for controlling engine revolutions includes an abrupt operationdetection step of detecting whether the motor-generator is abruptlyoperated; a torque calculation step of calculating an output torque ofthe hydraulic pump that is required in accordance with the abruptoperation of the motor-generator detected in the abrupt operationdetection step; a drop determination step of determining the possibilityof generating an engine revolution drop if the change of the outputtorque of the hydraulic pump calculated in the torque calculation stepexceeds a predetermined level; and a hybrid control step of controllingthe motor operation of the motor-generator by smoothly processing anabrupt operation signal of the motor-generator if it is determined thatthe engine revolution drop will occur in the drop determination step.

As preferred embodiments of the present invention, embodiments accordingto diverse possible combination of the above-described technicalfeatures may be included.

With the above-described construction, the engine revolution (RPM) drop,which occurs during the operation of the hybrid excavator or due to anabrupt operation change of the motor-generator attached to the engine,is prevented from occurring.

Also, the engine revolution (RPM) drop is prevented from occurring bysupplementing the engine output through the operation of themotor-generator as a motor when the engine revolution drop will occurdue to the operation of the construction machine such as an excavator.

Also, the engine revolution (RPM) drop is prevented from occurring bysmoothly changing and processing the driving signal of themotor-generator so that an abrupt change of the engine revolutions doesnot occur due to the abrupt operation of the motor-generator attached tothe engine of the hybrid construction machine.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other objects, features and advantages of the presentinvention will be more apparent from the following detailed descriptiontaken in conjunction with the accompanying drawings, in which:

FIG. 1 is a necessary torque output relationship diagram of an excavatorsystem in the related art;

FIG. 2 is a necessary torque output relationship diagram of a controlsystem for a hybrid construction machine according to an embodiment ofthe present invention;

FIGS. 3A and 3B are schematic block diagrams illustrating theconfiguration of a system for controlling engine revolutions for ahybrid construction machine according to an embodiment of the presentinvention;

FIG. 4 is a view illustrating the standard work data per engine mode ofan excavator;

FIG. 5 is a flowchart illustrating a method for controlling enginerevolutions for a hybrid construction machine according to anotherembodiment of the present invention; and

FIG. 6 is a flowchart illustrating a method for controlling enginerevolutions for a hybrid construction machine according to still anotherembodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Hereinafter, preferred embodiments of the present invention will bedescribed with reference to the accompanying drawings. The mattersdefined in the description, such as the detailed construction andelements, are nothing but specific details provided to assist those ofordinary skill in the art in a comprehensive understanding of theinvention, and thus the present invention is not limited thereto.

First, a system for controlling engine revolutions for a hybridconstruction machine according to an embodiment of the present inventionwill be described.

A control system for a hybrid construction machine will now bedescribed.

FIG. 2 is a necessary torque output relationship diagram of a controlsystem for a hybrid construction machine according to an embodiment ofthe present invention.

Referring to FIG. 2, a control system for a hybrid construction machineincludes an engine 10, a hydraulic pump 13 which is driven by the engine10 to drive a hydraulic actuator 15 with discharged hydraulic fluid, amotor-generator 17 which is driven by the engine 10 to generateelectricity and to drive the hydraulic pump 13 as a motor supplementingthe engine 10, and an energy storage device, e.g. a battery 19, which ischarged with electric energy generated by the motor-generator 17 andwhich supplies the electric energy for motor operation of themotor-generator 17. A system for controlling engine revolutions for ahybrid construction machine is a control system for reducing the changeof the engine revolutions (per minute) in the control system of thehybrid construction equipment.

The driving process of the engine 10 in the hybrid construction machinesystem will be described. If a work mode, for example, P-mode, H-mode,G1-mode, or F1-mode, is selected by a mode selection switch 1, theengine revolutions, that is, engine revolutions per minute (RPM), is setto 1900 RPM, 1800 RPM, 1700 RPM, 1400 RPM, or the like, and the enginerevolutions become reference engine revolutions. If fuel stored in afuel tank 4 is injected into the engine 10 through a fuel injectionsystem 3, the engine 10 is driven. A hybrid control means 50 receivesfeedback of torque necessary for the hydraulic actuator 15, that is, theoutput torque provided from the hydraulic pump 13, and controls powergeneration or motor operation of the motor-generator 17 through acontrol algorithm 51. In accordance with the power generation or motoroperation of the motor-generator, a necessary output of the existingengine 10 for providing the output torque of the hydraulic pump that isnecessary for the hydraulic actuator 15 is determined. In order for theexisting engine 10 to provide necessary output, the output revolutionsof the engine 10 and a required output or engine output torque are fedback to an electronic control unit (E-ECU) 3. The output torque of theengine 10 is varied by the variation of the fuel injection amount fromthe fuel tank 4 through the fuel injection system 3 that is controlledby the electronic control unit (E-ECU) 2.

FIG. 4 is a view illustrating the standard work data per engine mode ofan excavator, and shows engine outputs according to the excavator work.Examples of working mode may be P-mode, H-mode, G1-mode, G2-mode,F1-mode, and the like. The working modes are to fix the enginerevolutions of the engine 10. For example, if the working mode is set toP-mode, the engine 10 is set to 1900 RPM. If there is no load in theengine 10, the engine revolution is kept 1900 RPM, while if the loadbecomes larger due to the use of the excavator, the engine revolutionsbecomes a little lower than 1900 RPM, and more fuel is injected into theengine 10 through the self control system to keep the engine revolutionsof 1900 RPM.

FIG. 3A is a schematic block diagram illustrating the configuration of asystem for controlling engine revolutions for a hybrid constructionmachine according to an embodiment of the present invention.

Referring to FIG. 3A, in the system for controlling engine revolutionsfor a hybrid construction machine, the control system for a hybridconstruction machine includes an engine 10, a hydraulic pump 13 fordriving a hydraulic actuator 15, a motor-generator 17 which is driven bythe engine 10 to generate electricity and to drive the hydraulic pump 13as a motor supplementing the engine 10, and an energy storage device 19which is charged with generated electric energy and which supplies theelectric energy for motor operation of the motor-generator 17. Thesystem for controlling engine revolutions for a hybrid constructionmachine further include a torque detection means 40 for detecting theoutput torque of the hydraulic pump 13 that is required to drive thehydraulic actuator 15, and a hybrid control means 50.

The torque detection means 40 detects the output torque of the hydraulicpump that is required to drive the hydraulic actuator 15. The torquerequired to drive the hydraulic actuator 15 corresponds to the outputprovided from the hydraulic pump 13. Preferably, the torque detectionmeans 70 detects the output torque output from the hydraulic pump 13through the adjustment of a swash plate 14. Also, the torque that isnecessary for the system may be detected by detecting the opening areaor the output of a main control valve (MCV) 7. Referring to FIG. 2, theopening area of the main control valve (MCV) 7 is adjusted in accordancewith the output of a pilot value 6 through a user's operation of a lever5. Also, the output of the hydraulic pump 13 can be directly controlledby adjusting the swash plate 14 of the hydraulic pump 13 through a valveelectronic control unit (not illustrated) in accordance with the outputof the pilot valve 6 through the user's operation of the lever 5. Theflow rate discharged from the hydraulic pump 13 is adjusted according tothe opening area of the MCV 7 to be transferred to respective hydraulicsystems, or is adjusted by the swash plate 14 that is controlled by thevalve electronic control unit (not illustrated) to output torque that isrequired, for the construction machine, for example, the excavator.

The hybrid control means 50, if the change of the output torque of thehydraulic pump 13 detected by the torque detection means 40 exceeds apredetermined level and it is determined that an engine revolution dropwill occur in the engine 10, controls the motor operation of themotor-generator 17 to supplement the output of the engine 10.

FIG. 4 illustrates use areas of the engine in respective modes. Althoughuse areas in several modes are illustrated in FIG. 4, one mode isfixedly used for an actual excavator work for several hours. If load isabruptly increased during working, that is, if the torque that isrequired to drive the hydraulic actuator 15 is abruptly increased, therevolutions (RPM) of the engine 10 are considerably lowered. Even anexcavator in the related art adopts means for preventing such loweringof engine revolution, and for example, the lowering of the enginerevolution during working is limited to 100 RPM. In the case of thehybrid construction machine according to an embodiment of the presentinvention, the operation response speed of the motor-generator 17attached to the engine 10 is much faster than that of the engine 10, andthus the revolution (RPM) drop of the engine 10 can be prevented byadjusting the output of the motor-generator 17.

Preferably, if it is expected that the engine revolutions are loweredfor more than 100 RPM, it is determined that the revolution drop of theengine 10 will occur. Referring to FIG. 4, for example, if it is assumedthat the hydraulic actuator 15 is operated by an output of about 30 kWthat is received in H-mode, and the output torque of the hydraulic pump13 is abruptly increased from about 150 Nm to about 500 Nm due to arequired load of an output of 90 kW, it is expected that the enginerevolutions in the H-mode is lowered from about 1800 RPM to 1700 RPM. Inthis case, the required output torque of the hydraulic pump 13 iscompensated for by heightening the output of the motor-generator 17 bythe hybrid control means 50, and thus the revolution drop of the engine10 is prevented.

In another embodiment of the present invention, the hybrid control means50 controls the motor operation of the motor-generator 17 so as tosupplement the output of the engine 10 if the change of the outputtorque of the hydraulic pump 13 exceeds the predetermined level due toan abrupt increase of load during working and thus it is determined thatthe engine revolution drop is occurring. That is, by operating themotor-generator 17 as a motor to supplement the output of the engine 10,the revolutions of the engine 10 is kept roughly constant even if anabrupt output increase is required, and thus the abrupt output can beobtained with the revolution (RPM) drop of the engine 10 prevented.

For example, in the case of the engine revolution drop occurring due toan abrupt operation of the excavator, the output torque of the hydraulicpump 13 that is required in the hydraulic actuator 15 is calculated inadvance, and if the occurrence of the revolution drop is predicted, themotor-generator 17 is driven as a motor to add the output to the engine10, and thus the engine revolution drop is prevented.

FIG. 3B is a schematic block diagram illustrating the configuration of asystem for controlling engine revolutions for a hybrid constructionmachine according to another embodiment of the present invention.

In a hybrid construction machine system, if the motor-generator 17attached to the engine 10 is abruptly operated, the engine revolutiondrop may occur. Referring to FIG. 3B, the system for controlling enginerevolutions according to an embodiment of the present invention furtherincludes a driving control means for controlling the power generation orthe motor operation of the motor-generator 17, and an abrupt operationdetection means 70 for detecting whether motor-generator 17 is abruptlyoperated.

The hybrid control means 50 smoothly processes an abrupt operationsignal of the motor-generator 17 and supplies the processed signal tothe driving control means 60 if the change of the output torque of thehydraulic pump 13 that is required according to the abrupt operation ofthe motor-generator 17 detected by the abrupt operation detection means70 exceeds the predetermined level and thus it is determined that theengine revolution drop will occur. That is, in this embodiment of theinvention, by distorting a predetermined amount of the driving signal ofthe motor-generator 17 and smoothly applying the driving signal, theengine revolution (RPM) drop is prevented.

Next, a method for controlling engine revolutions for a hybridconstruction machine according to another embodiment of the presentinvention will be described. The explanation of portions overlapping theexplained portions of the system for controlling engine revolutions fora construction machine according to an embodiment of the presentinvention as described above will be omitted. The method for controllingengine revolutions for a hybrid construction machine is applied to thecontrol system for a hybrid construction machine which includes anengine 10, a hydraulic pump 13 which is driven by the engine 10 to drivea hydraulic actuator 15 with discharged hydraulic fluid, amotor-generator 17 which is driven by the engine 10 to generateelectricity and to drive the hydraulic pump 13 as a motor supplementingthe engine 10, and an energy storage device 19 which is charged withelectric energy generated by the motor-generator 17 and which suppliesthe electric energy for motor operation of the motor-generator 17.

FIG. 5 is a flowchart illustrating a method for controlling enginerevolutions for a hybrid construction engine output if it is determinedthat the engine revolution drop will occur in the drop determinationstep S200.

In a preferred embodiment of the present invention, in the dropdetermination step S200, the possibility of generating an enginerevolution drop is determined if the change of the output torque of thehydraulic pump 13 due to an abrupt increase of load during the operationexceeds a predetermined level.

FIG. 6 is a flowchart illustrating a method for controlling enginerevolutions for a hybrid construction machine according to still anotherembodiment of the present invention.

In a hybrid construction machine system, if the motor-generator 17attached to the engine 10 is abruptly operated, the engine revolutiondrop may occur. Referring to FIG. 6, the method for controlling enginerevolutions according to still another embodiment includes an abruptoperation detection step S500, a torque calculation step S1000, a dropdetermination step S2000, and a hybrid control step S3000.

In the abrupt operation detection step S500, it is detected whether themotor-generator 17 is abruptly operated.

In the torque calculation step S1000, the output torque of the hydraulicpump 13, which is required in accordance with the abrupt operation ofthe motor-generator 17 that is detected in the abrupt operationdetection step S500, is calculated.

In the drop determination step S2000, the possibility of generating theengine revolution drop of the engine 10 is determined if the change ofthe output torque of the hydraulic pump 13 calculated in the torquecalculation step S1000 exceeds a predetermined level.

In the hybrid control step S3000, the motor operation of themotor-generator 17 is controlled by smoothly processing the abruptoperation signal of the motor-generator 17 if it is determined that theengine revolution drop of the engine 10 will occur in the dropdetermination step S2000.

As described above, the preferred embodiments of the present inventionhave been described in detail with reference to the accompanyingdrawings. The aspects and features of the present invention and methodsfor achieving the aspects and features will be apparent by referring tothe embodiments as described above with reference to the accompanyingdrawings. However, the present invention is not limited to theembodiments as described above, but can be implemented in diverse forms.Although preferred embodiment of the present invention has beendescribed for illustrative purposes, those skilled in the art willappreciate that various modifications, additions and substitutions arepossible, without departing from the scope and spirit of the inventionas disclosed in the accompanying claims.

What is claimed is:
 1. A method for controlling engine revolutions in acontrol system for a hybrid construction machine, including an engine, ahydraulic pump which is driven by the engine to drive a hydraulicactuator with discharged hydraulic fluid, a motor-generator which isdriven by the engine, to generate electricity and to drive the hydraulicpump as a motor supplementing the engine, and an energy storage devicewhich is charged with electric energy generated by the motor-generatorand which supplies the electric energy for motor operation of themotor-generator, the method comprising: a torque detection step ofdetecting an output torque of the hydraulic pump that is required todrive the hydraulic actuator; a drop determination step of determiningthe possibility of generating an engine revolution drop if the change ofthe output torque of the hydraulic pump detected in the torque detectionstep exceeds a predetermined level; and a hybrid control step ofcontrolling the motor operation of the motor-generator so as tosupplement the engine output if it is determined that the enginerevolution drop will occur in the drop determination step, wherein thedrop determination step determines the possibility of generating theengine revolution drop if the change of the output torque of thehydraulic pump exceeds the predetermined level due to an abrupt increaseof load during operation.